Method and system for analysis and shape optimization of physical structures using a computerized algebraic dual representation implicit dimensional reduction

Abstract

A method and system for simulating and analyzing the behavior of a structural component of a computerized model in response to a simulated event to determine an optimized shape for the component is disclosed. The shape is optimized using an implicit dimensional reduction rather than an explicit geometric replacement by discarding data of a 3D discretization that has little or no bearing on the performance of the component to a simulated event. The reduced dataset is then collapsed onto a lower dimension projection that is applied over a force vector that is representative of the simulated event to determine the behavior of the component to the simulated event. Optimization tools may then be used to modify the physical attributes of the component and performance of the component once again simulated until an optimized component is determined.

1. A method of analyzing behavior of a component of a computerized design model in response to a load, comprising:
 (A) characterize the component as one of a beam, a plate, and a solid from a first ratio of the height and the length of the component and a second ratio of the width and the length of the component; 
 (B) performing a 3D finite element discretization of the 3D geometry of the component; 
 (C) generating a lower dimension structural element stiffness matrix from the 3D discretization, the stiffness matrix capturing bending stresses and strains of a virtual structural element; 
 (D) applying the stiffness matrix on a force vector representative of a simulated load on the virtual structural element; and 
 (E) determining a shape of the virtual structural element as deflected by the force vector. 
 
     
     
       2. The method of  claim 1  wherein the 3D finite element discretization includes a 3D finite element mesh. 
     
     
       3. The method of  claim 1  wherein generating the stiffness matrix includes removing data elements of the 3D finite element discretization that negligibly impact bending stresses and strains of the virtual structural element to provide a reduced dataset and projecting the reduced dataset onto a reduced projection matrix. 
     
     
       4. A computer readable, non-transitory, storage medium having a computer program thereon representing a set of instructions that when executed by a computer causes the computer to perform a shape optimization of a 3D structural element of a computer model, the structural element having a 3D geometry and physics characterizing the physical response of the 3D structural element to an applied force, wherein the shape optimization is performed by:
 characterizing the 3D structural element as one of a beam, a plate, and a solid from a first ratio of the height and the length of the 3D structural element and a second ratio of the width and the length of the selected 3D structural element; 
 discretizing the 3D geometry of the 3D structural element from a 3D finite element mesh, the discretization providing a 3D bending stiffness matrix; 
 capturing the physics with a lower dimension structural element analysis, the physics represented in a lower dimension structural element stiffness matrix; and 
 applying the lower dimension structural element stiffness matrix on a force vector representative of a force applied to the structural element to determine a simulated response of the structural element to the force. 
 
     
     
       5. The computer readable, non-transitory, storage medium of  claim 4  wherein the set of instructions further causes the computer to couple the lower dimension structural element stiffness matrix and the force vector before determining the simulated response of the structural element to the force. 
     
     
       6. The computer readable, non-transitory, storage medium of  claim 5  wherein the set of instructions causes the computer to generate a Lagrangian system that couples the lower dimension structural element stiffness matrix and the force vector and then causes the computer to solve the Langrangian system to derive 3D degrees of freedom for the 3D finite element mesh. 
     
     
       7. The computer readable, non-transitory, storage medium of  claim 4  wherein the 3D bending stiffness matrix is representative of non-negligible bending stresses and strains on the structural element. 
     
     
       8. The computer readable, non-transitory, storage medium of  claim 4  wherein the lower dimension structural element stiffness matrix is a 1D beam stiffness matrix. 
     
     
       9. The computer readable, non-transitory, storage medium of  claim 8  wherein the structural element is a beam-like element. 
     
     
       10. The computer readable, non-transitory, storage medium of  claim 4  wherein the lower dimension structural element stiffness matrix is a 2D plate stiffness matrix. 
     
     
       11. The computer readable, non-transitory, storage medium of  claim 10  wherein the structural element is a plate-like element. 
     
     
       12. A computerized system for evaluating design changes to a computerized model having a plurality of components, and comprising a computer programmed to:
 (a) access the computerized model and select a 3D component of the computerized model whose behavior in response to a simulated parameter is to be evaluated; 
 (b) characterize the selected 3D component as one of a beam, a plate, and a solid from a first ratio of the height and the length of the 3D selected component and a second ratio of the width and the length of the selected 3D component; 
 (c) discretize a 3D geometry of the selected 3D component with a 3D finite element discretization to provide a 3D dataset; 
 (d) identify physical parameters of the 3D component that have a negligible effect on the behavior of the 3D component to the simulated parameter; 
 (e) remove data from the 3D dataset corresponding to the physical parameters that have a negligible effect on the behavior of the 3D component to the simulated parameter to provide a reduced dataset; 
 (f) project the reduced dataset onto a lower dimension matrix; 
 (g) apply the simulated parameter to the lower dimension matrix; and 
 (h) determine the behavior of the 3D component in response to the simulated parameter. 
 
     
     
       13. The computerized system of  claim 12  wherein the computer is further programmed to iteratively modify the shape of the selected component and execute acts (c) through (h) for each shape modification to determine an optimized shape for the selected 3D component given a set of shape constraints. 
     
     
       14. A method of analyzing behavior of a component of a computerized design model in response to a load, comprising:
 (A) characterizing the component as a beam, a plate, or a solid: 
 (B) performing a 3D finite element discretization of the component; 
 (C) generating a 1D beam stiffness matrix from the 3D discretization, the beam stiffness matrix capturing bending stresses and strains of a virtual beam; 
 (D) applying the beam stiffness matrix on a force vector representative of a simulated load on the virtual beam; and 
 (E) determining a shape of the virtual beam as deflected by the force vector. 
 
     
     
       15. A computerized system for evaluating design changes to a computerized model having a plurality of components, and comprising a computer programmed to:
 (a) access the computerized model and select a 3D component of the computerized model whose behavior in response to a simulated parameter is to be evaluated; 
 (b) characterize the selected 3D component as one of a beam, a plate, and a solid from a first ratio of the height and the length of the 3D selected component and a second ratio of the width and the length of the selected 3D component; 
 (c) discretize a geometry of the selected 3D component with a 3D finite element discretization to provide a 3D dataset, the 3D dataset defining a corresponding stiffness matrix; 
 (d) identify physical parameters of the 3D component that have a negligible effect on the behavior of the 3D component to the simulated parameter; 
 (e) remove data from the 3D dataset corresponding to the physical parameters that have a negligible effect on the behavior of the 3D component to the simulated parameter to provide a reduced dataset; 
 (f) project the reduced dataset onto a lower dimension matrix; 
 (g) apply the simulated parameter to the lower dimension matrix; 
 (h) determine the behavior of the component in response to the simulated parameter; and 
 (i) iteratively modify the shape of the selected component and execute acts (c) through (h) for each shape modification to determine an optimized shape for the selected component given a set of shape constraints. 
 
     
     
       16. The computerized system of  claim 15  wherein the computer is programmed to project the lower dimension matrix by applying the reduced dataset on a force vector representative of the simulated parameter.